Safety Order: Leitner Poma detachable installations
September 13, 2012
This safety order is issued pursuant to section 31 of the Safety Standards Act. A person affected by this safety order may appeal this order in writing to the Safety Standards Appeal Board within 30 days. The appeal process is set out on the Safety Standards Appeal Board's website.
This safety order, No: SO-PR 2012-02, applies to all Leitner Poma detachable above surface passenger ropeways and the Safety Order Response Form SO 2012-02.
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It has been determined through consultation with affected operators and Leitner Poma of America (LPOA), in addition to BCSAs internal review, that the proposed solution to “X-Y” sheave assembly adjustment bolt failures identified in 2011 is not viable. Therefore; the installation of “X-Y” sheave assembly axle adjustment bolt safety kits proposed by LPOA is no longer required on the affected detachable passenger ropeway installations. New requirements to mitigate these types of failures have been identified and are explained in Part 2 of this safety order.
The paragraphs below explain the original safety risk identified by BCSA that prompted issuance of the former Safety Order
Incidents have been reported to the BCSA where “X-Y” sheave assembly axle adjustment bolts on Leitner Poma detachable passenger ropeways have failed. These failures typically result in a displacement of the sheave assembly axle resulting in the haul rope deviating from its prescribed path. In all cases thus far the haul rope movement is detected by the “cable position sensors” and the installation is stopped before a full deropement occurred. Three of theses failures resulted in manual evacuations of the passenger ropeways affected. One failure has resulted in the bolt dropping to the ground potentially exposing passengers and persons underneath the lift line to injury or death. Due to the movement of the axle as a result of these failures there is potential for deropements to occur that could result in injuries or further damage to equipment.
BCSA performed an analysis which included consultation with the manufacturer, operators of the affected passenger ropeways and a metallurgical analysis of the bolts in question conducted by an independent engineering firm. The results of the analysis have prompted the BCSA to require passenger ropeway contractors to take the actions identified in this safety order.
All of the incident data accumulated by BCSA indicates that only detachable passenger ropeways have been affected to date; however if failures begin to emerge on fixed grip installations another safety order may be issued by the BCSA to address those installations.
Part 2: Requirement(s) of this safety order
All operators of LPOA detachable above surface ropeways must complete requirements 1 and 2 prior to operation for the 2012/2013 winter operating season.
- Complete the detailed requirements identified in LPOA Service Notice No: 07262012. This includes detailed setup instructions of sheave assembly axles with respect to “X-Y” adjustment bolts, installation of new hardware where required and installation of 3040409 Axle Block Safety where required. A copy of LPOA Service Notice No: 07262012 is attached to this safety order.
- Replace all existing 1 1/8” A325 Cut thread “X-Y” bolts. All of the A325 cut thread “X-Y” bolts must be replaced with an A325 class 2A rolled thread bolt. Any existing A325 class 2A rolled thread “X-Y” bolts that show signs of failure or potential failure must immediately be reported to a BCSA Safety Officer.
- After the 2013/2014 winter operating season, a 10% sample rate of all A325 class 2A rolled thread “X-Y” bolts must be non-destructively tested utilizing the wet fluorescent magnetic particle inspection method performed by an appropriately certified test person. These tests shall be performed on bolts from sheave assemblies that receive the highest loads according to your “as- built” ropeline calculation or on sheave assemblies where previous failures of these bolts have occurred. Any bolts that show signs of failure or potential failure during testing must be immediately reported to a BCSA Safety Officer to determine if an increase in the sample rate is required on that particular installation. All test reports must be submitted to the BCSA prior to the 2014/2015 winter operating season. Subsequent to the receipt of the test results, BCSA may require further testing at a similar interval.
BCSA is aware of newer LPOA detachable passenger ropeway installations where an axle stop device and/or ASTM A325 bolts with class 2A rolled threads may already be in place. This must be confirmed by the manufacturer in writing and submitted to BCSA in support of your response to this safety order.
All affected passenger ropeway contractors must submit the attached response form to confirm completion of requirements 1 and 2 prior to the 2012/2013 winter operating season. The response form must be completed in its entirety.
Part 3: Details of Issue
This safety order is being issued to the following: All passenger ropeway contractors operating Leitner Poma detachable above surface ropeways.
Part 4: Details of Ordering Safety Manager or Safety Officer – Please read following page
I certify that I am authorized to issue this safety order in accordance with section 15 (d) of the Safety Standards Act or that I have been delegated this power under section 15 (g) of the Safety Standards Act
Date: September 13, 2012
Provincial Safety Manager, Passenger Ropeways and Amusement Devices